Vapor permeable fabric constructs with static or dynamic antimicrobial compositions

Abstract

Protective, multi-layered, breathable fabric constructs having dynamic or static antimicrobial compositions incorporated into adhesive components. The flexible constructs employ a fabric layer and a breathable coating layer applied to the fabric. Under certain preferred embodiments, the fabric constructs also employ an energy dissipating fiber material disposed opposite the coating layer. Also, the present invention teaches a method of protecting a valuable or sensitive object from damage caused by corrosion, weather, biomass, or other environmental related conditions using the fabric material. The fabric constructs may be post-formed using heat or other methods to create shaped-to-form covers.

We claim: 
     
       1. A fabric construct comprising:
 a porous fabric layer; 
 an adhesive layer applied to said fabric layer including an adhesive comprising an antimicrobial compound chemically bonded to a vapor corrosion inhibitor; 
 a fiber layer applied to the adhesive layer; and 
 a waterproof, moisture vapor permeable polymeric composition comprising a cross-linked polyurethane coating applied to and embedded in the porous fabric on the side opposite the fiber layer without an adhesive binding said composition coating to said porous fabric; 
 
       wherein the fiber layer comprises flocked fibers or a non-woven fabric. 
     
     
       2. The fabric construct of  claim 1  wherein the porous fabric layer is a woven material. 
     
     
       3. The fabric construct of  claim 1  wherein the adhesive layer is formed from a foamed hydrophilic adhesive composition selected from the group consisting of acrylic latexes, urethanes, and epoxies. 
     
     
       4. The fabric construct of  claim 2  wherein the porous fabric layer is marked with a design, and the waterproof, moisture vapor permeable polymeric composition cross-linked coating is clear to make the design visible. 
     
     
       5. The fabric construct of  claim 3  wherein the adhesive composition comprises encapsulated vapor phase corrosion inhibitors. 
     
     
       6. The fabric construct of  claim 4  wherein the adhesive composition is modified with titanates and/or zirconates. 
     
     
       7. The fabric construct of  claim 1  wherein said adhesive layer comprises a foamed adhesive layer. 
     
     
       8. The fabric construct of  claim 1  wherein said adhesive layer is obtained by applying multiple coats. 
     
     
       9. The fabric construct of  claim 1  wherein the fiber layer comprises flocked fibers selected from rayon, acetate, nylon, polyolefin, acrylic, polyester, carbon fiber, cotton, hemp, and wool. 
     
     
       10. The fabric construct of  claim 9  wherein said flocked fibers have an average denier of between 0.5 and 90.0. 
     
     
       11. The fabric construct of  claim 9  wherein said flocked fibers have an average length between 0.25 mm and 20.0 mm. 
     
     
       12. The fabric construct of  claim 9  wherein said flocked fibers are capable of wicking moisture in the direction of the porous fabric layer. 
     
     
       13. The fabric construct of  claim 1  wherein the moisture vapor permeable polymeric composition forms a layer having an average thickness of 0.5 mil to 10 mils. 
     
     
       14. The fabric construct of  claim 1  wherein the moisture vapor permeable polymeric composition forms a layer having a water vapor transmission rate of at least 100 grams/square meter/day at 37.8° C. and 100% relative humidity. 
     
     
       15. The fabric construct of  claim 1 , wherein at least one of the porous fabric of the fabric layer, the adhesive composition of the adhesive layer, the fiber layer, and the vapor permeable polymeric composition comprises a fire resistant additive. 
     
     
       16. The fabric construct of  claim 1 , wherein the fiber layer comprises flocked fibers. 
     
     
       17. The fabric construct of  claim 1 , wherein the fiber layer comprises a non-woven fabric. 
     
     
       18. The fabric construct of  claim 1 , wherein the adhesive layer comprises a foamed adhesive composition. 
     
     
       19. The fabric construct of  claim 1 , wherein the adhesive layer comprises a composition rendered hydrophilic by incorporation of titanate or zirconate compounds having hydrophilic properties. 
     
     
       20. The fabric construct of  claim 1 , wherein the vapor permeable polymeric composition further comprises a flattening agent. 
     
     
       21. A fabric construct according to  claim 1 , wherein the adhesive comprises hexamethylenetetramine. 
     
     
       22. A waterproof protective cover that provides for water vapor to escape through the cover from a protected volume enclosed by the cover, formed from a fabric construct according to  claim 1 . 
     
     
       23. A waterproof protective cover that provides for water vapor to escape through the cover from a protected volume enclosed by the cover, formed from a fabric construct according to  claim 16 . 
     
     
       24. A protective cover prepared by sewing or thermoforming a fabric construct according to  claim 1 . 
     
     
       25. A method for making a fabric construct according to  claim 16 , comprising:
 applying a coating of aliphatic polyurethane on one side of a porous fabric; 
 applying a foamed adhesive composition to the side of the porous fabric opposite the polyurethane coating; and 
 applying flocked fibers to the foamed adhesive composition. 
 
     
     
       26. A method according to  claim 25 , wherein applying the foamed adhesive composition comprises applying a pre-coat and a topcoat, wherein the pre-coat and the topcoat comprise vapor phase corrosion inhibitors (VCI) and a coupling agent selected from titanates and zirconates. 
     
     
       27. A method for making a construct according to  claim 1 , comprising:
 applying a hot melt adhesive composition to one side of a porous fabric, wherein the hot melt adhesive composition comprises a non-pressure sensitive thermoplastic hot melt rubber and vapor phase corrosion inhibitor (VCI); 
 applying a foamed adhesive composition onto the adhesive composition comprising the thermoplastic hot melt rubber; 
 applying flocked fibers onto the foamed adhesive composition; and 
 applying the vapor permeable polymer composition onto the porous fabric on the side opposite the adhesive and the flocked fibers. 
 
     
     
       28. A method according to  claim 27 , wherein the hot melt adhesive composition comprises a hot melt block rubber. 
     
     
       29. A method according to  claim 28 , wherein the foamed adhesive composition is selected from acrylic latexes, urethanes, and epoxies. 
     
     
       30. A method for making a construct according to  claim 16 , comprising:
 applying a vapor permeable polyurethane composition onto one side of a porous fabric; 
 applying a non-pressure sensitive hot melt block rubber composition comprising 
 
       VCI onto the side of the porous fabric opposite the polyurethane coating;
 applying a foamed adhesive composition onto the adhesive composition comprising the thermoplastic hot melt rubber; and 
 applying flocked fibers onto the foamed adhesive composition. 
 
     
     
       31. A method of making a construct according to  claim 17  comprising; applying a coating of aliphatic polyurethane on one side of the porous fabric; applying a hot melt adhesive composition to the side of the porous fabric opposite the polyurethane, wherein the hot melt adhesive composition comprises a pressure sensitive thermoplastic hot melt rubber and vapor phase corrosion inhibitor (VCI); and
 adhering the non-woven fabric to the hot melt adhesive composition. 
 
     
     
       32. A method of making a construct according to  claim 17  by lamination, the method comprising:
 applying a coating of aliphatic polyurethane on one side of a porous fabric to make a first lamination part; 
 applying a layer of adhesive to one side of a non-woven fabric to make a second lamination part; and 
 forming the construct by laminating the porous fabric side of the first to the adhesive side of the second part.